Assembly

ABSTRACT

The present invention relates to a modular containment assembly of novel component parts which by virtue of its inherent versatility is straightforward and inexpensive to assemble whilst providing improved performance and cleanliness thereby minimising the potential for product contamination. More particularly, the component parts are an operator booth and a modular structure comprising a plurality of unitary frameworks between which (in use) is induced an airflow.

BACKGROUND ART

[0001] 1. Field of the Invention

[0002] The present invention relates to a novel modular containmentassembly comprising certain components, in particular to a down flowmodular containment assembly, and to the components themselves.

[0003] 2. Background Art

[0004] In conventional containment assemblies for use in (for example)handling pharmaceuticals, the air quality in the operator booth may becontrolled using forced ventilation. One category of forced ventilationis “down flow” in which surrounding air is drawn downwardly to entraincontaminants to a level below the handling area (eg to a level below thetypical operators breathing zone). For down flow containment, exhaust isusually carried out at low level relative to the source of thecontaminant.

[0005] Due to the demanding requirements of current Good ManufacturingPractices exercised within the pharmaceutical manufacturing industry andto the required containment performance and operator exposure levels,conventional down flow containment assemblies are in general complexunitary structures which are difficult and relatively expensive toassemble.

[0006] The present invention seeks to overcome certain of thedisadvantages of the conventional assemblies by providing a simpler andmore hygienic containment assembly without compromising the performanceof the assembly (ie which meets the strict industrial operatingparameters such as the the Good Manufacturing Practices of thepharmaceutical industry). In particular, the present invention providesa modular containment assembly of novel component parts which by virtueof its inherent versatility is straightforward and inexpensive toassemble whilst providing improved performance and cleanliness therebyminimising the potential for product contamination.

SUMMARY OF THE INVENTION

[0007] Thus viewed from one aspect the present invention provides amodular containment assembly comprising components between which (inuse) is induced an airflow, said components being:

[0008] a modular structure comprising a plurality of unitary frameworksstacked to form a network of discrete housings;

[0009] an operator booth of box-like configuration having a rear wallpositioned adjacent to the modular structure, wherein the modularstructure is adapted at or near to its lower end to receive the airflowfrom the operator booth and at or near to its upper end to transmit theairflow to the operator booth, and the rear wall of the operator boothis adapted at or near to its lower end to transmit the airflow to themodular structure; and

[0010] means for inducing the airflow downwardly in the operator booth.

[0011] The versatility of the modular containment assembly of theinvention is such that any of the individual components may be readilyassembled and supplied to a user with the intention of putting theinvention into effect in combination with the other components which mayalready be available to the user.

[0012] Typically, the assembly of the invention is adapted so that airfalls in an undisturbed, non-turbulent manner past the region of theoperator booth in which the operator operates (“the operator breathingzone”) at a predetermined velocity. Preferably the components of theassembly are adapted to attain perfect laminar flow (PLF) of air.Preferably the modular structure at or near to its upper end comprisesPLF material (eg a PLF screen) through which the airflow passes to theoperator booth.

[0013] A preferred embodiment of the modular containment assembly of theinvention further comprises a plenum arrangement adjacent to an openceiling of the operator booth, wherein the plenum arrangement is capableof transmitting the airflow from at or near to the upper end of themodular structure downwardly into the operator booth.

[0014] Preferably the plenum arrangement comprises one or more plenumchambers. The or each chamber may be generally adapted to minimise theplenum volume. Preferably the or each plenum chamber is adapted tocontribute to perfect laminar flow (PLF).

[0015] The or each plenum chamber preferably comprises a metal(preferably steel) base frame coated on two sides with a material of apreset tension. The base frame provides a specific pressure drop whichmay contribute to the perfect laminar flow (PLF). The base frameconveniently has a ladder-like configuration. For example, the baseframe comprises two elongate side members joined in parallel spacedapart relationship by a plurality of transverse members. On the lowerface of the base frame there may be mounted PLF material (eg a PLFscreen). Laminar flow light fittings may be mounted to the lower face ofthe frame (eg the side members) if desired.

[0016] A profiled canopy may be secured to the upper face of the baseframe. Preferably the profiled canopy is capable of providing a smoothand interrupted airflow from the modular structure into the PLFmaterial. For example, the profiled canopy may have a substantiallyvertical open end (eg a substantially square open end) through which maybe transmitted airflow from the modular structure. The substantiallyvertical open end may be defined by two side walls joined insubstantially parallel spaced apart relationship by an integral rearwall which curves inwardly away from the open end.

[0017] The substantially vertical open end may be fitted with a liquidseal. For this purpose the ends of the two side walls and integral rearwall may be provided with a securing flange.

[0018] The substantially vertical open end may fitted with a PLF panelto advantageously contribute to even distribution of air across thewidth and down the length of the plenum chamber.

[0019] The or each plenum chamber may consist of only one external sealand is advantageously constructed without external sealants therebyeliminating a source of possible contamination whilst maintaining thedesired level of cleanliness.

[0020] Preferably the or each plenum chamber is detachably mounted tothe ceiling of the operator booth (eg is a plug-in/plug-out arrangement)which advantageously makes it sufficiently versatile to be attached toany type of operator booth.

[0021] In a preferred embodiment of the modular containment assembly ofthe invention, the modular structure comprises an at least partiallyopen front face at or near to its lower end and adjacent to the rearwall of the operator booth, wherein the rear wall of the operator boothat or near to its lower end comprises an elongate gap capable oftransmitting airflow from the operator booth to and through the at leastpartially open front face of the modular structure. Preferably the atleast partially open front face is adapted to mount a pre-filter (eg byincorporating a filter retainer panel).

[0022] Although the modular structure may be manufactured from anysuitable metal (such as steel or aluminium), steel is generallypreferred in terms of costs and flexibility to accommodate design change(eg future developments in filter design or other internal componentdesign).

[0023] In a preferred embodiment of the modular containment assembly ofthe invention, each unitary framework is a metal (eg an aluminium orsteel) frame construction. A frame construction advantageously minimisesthe potentially contaminated volume of the modular structure.

[0024] Each unitary framework provides a discrete housing which may betailored to meet the requirements and conform to the size of a desiredinternal component. Examples of internal components may include part ofthe means for inducing the airflow such as inter alia one or morefilters or a fan unit. For example, one or more filters may be housed ina lower discrete housing and a fan unit in an upper discrete housing ofthe modular structure.

[0025] If desired, one or more of the unitary frameworks may bepanelled. Suitable panels include standard pressed or vacuum formedfilter retainer panels. Such panels may be attached using a proprietaryadhesive tape and adhesive liquid seal to eliminate any tendency forproduct entrapment whilst giving overall structural rigidity. Theadhesive tape provides a seal for the panel and the liquid adhesive sealensures a substantially leak-free join. Preferred are sheet metal (egsteel) panels which (when used with a compatible (eg steel) framework)may be secured in suitable manner (eg using adhesives, tapes orfasteners).

[0026] Preferably, each unitary framework comprises a plurality ofstruts (eg a plurality of horizontal struts and a plurality of verticalstruts). Particularly preferably the struts are uniform therebyminimising the number of parts which need to be specially manufactured.For example, the uniform struts may be of standard dimensions egstandard 500 mm and/or 700 mm lengths may be used to assemble theunitary framework allowing any operator booth of width up to 5 metres tobe used. Preferably each strut of the unitary framework has a uniformdrill pattern ensuring complete modularity.

[0027] Each strut of the unitary framework may be fabricated from metal(eg aluminium or steel) extrusions and joined in a conventional manner(eg permanently joined with an air tight corner piece). Preferably theinternal joins between struts are flush and closed to eliminateentrapment areas. Each strut may comprise an internal elongate flangewhich provides a means for securing the unitary framework to an adjacentunitary framework (eg by providing a surface through which a fastenersuch as a bolt may pass) and to act as a seal zone between adjacentunitary frameworks.

[0028] Preferably one or more of the unitary frameworks is box-like (egcuboidal or cubic). Adjacent unitary frameworks may be fastened togetherto form the modular structure using any conventional fastener eg boltsand may be of variable dimensions (eg variable height) as desired.

[0029] A unitary framework may be adapted to vertically mount a filtersuch as a pre-filter (eg by incorporating a filter retainer panel). Sucha unitary framework would generally be positioned at or near to thelower end of the modular structure and may for example be the lowermostunitary framework of the modular structure.

[0030] A unitary framework may be adapted to horizontally mount a filtersuch as a hepafilter. Such a unitary framework would generally bepositioned above the lowermost unitary framework of the modularstructure.

[0031] A unitary framework may be adapted to mount a fan unit. Such aunitary framework would generally be positioned at or near to the upperend of the modular structure and may for example be the uppermostunitary framework of the modular structure.

[0032] In a preferred embodiment of the modular containment assembly ofthe invention, the means for inducing the airflow comprises a fan unitdriven by a flange mounted inverter controlled motor which ensuressmooth drive via a flexible coupling. The fan motor unit is placed downflow from the filters ensuring that the unit is only exposed to cleanfiltered air. The fan unit may be seated on highly compressedanti-vibration mounts to ensure that no vibration is passed onto theadjacent parts of the booth.

[0033] Preferably, the operator booth incorporates a clean roompartition system adapted to meet the requirements of the pharmaceuticalindustry. Preferably, the operator booth comprises individual panelscapable of being locked together. This advantageously eliminates theneed for fasteners and reduces assembly time. Preferably, the operatorbooth is adapted so that the number of panel joins are minimised (eg 5or less) and are hygienically sealed by a thin bead of silicone.

[0034] The panels of the operator booth may be adapted to provideexceptional noise damping and vibration isolation. The panels mayprovide increased rigidity to support an upper mounted plenumarrangement. The rear wall of the operator booth comprises a “serviceband” which may contain inter alia control buttons, the electrical andgauge piping, inverter and commissioning interface which permits entirecommissioning from the interior of the booth. For example, the motormounted inverter may be controlled via a link from the service band forease of commissioning and set up. Preferably the service band has anaerofoil shaped exterior profile which improves dust capture in the workarea by accelerating airflow over its surface.

[0035] Each component of the modular down flow booth of the invention isitself independently patentably significant.

[0036] Thus viewed from a further aspect the present invention providesa modular structure as hereinbefore defined.

[0037] The modular nature of the modular structure makes it easier andless costly to manufacture than a large, complex unitary structure (eg asheet metal fabrication) fulfilling the same function. The modularstructure is extremely rigid and provides a steady foundation for theattachment of an operator booth. A preassembled modular structure may beadvantageously transported (eg using a fork-lift transporter) onto asite in ready-to-run condition so that only internal components (such asfilters, electrical components and piping) need to be added.Alternatively it may be provided to the user in disassembled form forassembly on site. The modular structure has the added advantage that thevolume within the network of housings which has the potential to becontaminated is minimised.

[0038] Viewed from a yet further aspect the present invention provides aplenum chamber as hereinbefore defined.

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The invention will now be described in a non-limitative sensewith reference to the accompanying Figures in which:

[0040]FIG. 1 illustrates a modular containment assembly in accordancewith an embodiment of the invention;

[0041]FIG. 2 illustrates a modular containment assembly in accordancewith an embodiment of the invention together with associated down flow(front perspective view);

[0042]FIG. 3 illustrates a modular containment assembly in accordancewith an embodiment of the invention together with associated down flow(side view);

[0043]FIG. 4 illustrates a disassembled unitary framework of a modularstructure in accordance with an embodiment of the invention;

[0044]FIG. 5a and 5 b illustrate an assembled unitary framework of amodular structure in accordance with an embodiment of the invention in(a) unpanelled and (b) panelled form;

[0045]FIG. 6 illustrates a perspective view of a disassembled plenumchamber of a plenum arrangement of the invention; and

[0046]FIG. 7 illustrates an assembled unitary framework of a modularstructure in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

[0047] With reference to FIG. 1, there is shown (in partially exposedview) an embodiment of the modular containment assembly of the inventiondesignated generally by reference numeral 1. The assembly comprises arear modular structure comprising a number of stacked unitary frameworks2 each having a frame construction (discussed below). The exposed viewof the interior of the operator booth 3 shows panels 4 which are lockedtogether without the need for fasteners. The rear wall of the booth 5incorporates a laminar flow service band 6 from which the operator cancontrol the assembly using the control panel 7. In the ceiling region ofthe operator booth, there is mounted a plenum arrangement comprising anumber of plenum chambers 8 (discussed below).

[0048]FIGS. 2 and 3 are intended to illustrate in detail the airflow inthe embodiment described in FIG. 1. In the operator booth, the airflowis directed downwardly to and through an elongate opening 20 in thelower part of the rear wall 21. In the lowermost discrete housing 2 a ofthe modular structure, there is vertically mounted a FP95 pre-filter 31through which air flows to a vertically adjacent discrete housing 2 bwhich contains a horizontally mounted EU13 Gel Seal HEPAfilter 32. Inthe uppermost discrete housing 2 c, there is provided a fan unit 33which draws air into the plenum chamber 8 and through the laminar flowmaterial downwardly into the operator booth.

[0049] The components of a unitary framework 2 of the modular structureof the invention are shown in disassembled view in FIG. 4. In thisparticular case, the unitary framework 2 is adapted to vertically mounta pre-filter (see 2 a in FIGS. 2 and 3). The unitary framework 2comprises a plurality of uniform struts arranged vertically andhorizontally to form a regular box-like framework. Each vertical andhorizontal strut is a standard length R25-9 aluminium extrusion 40 andthey are interconnected by means of air tight P25-3 corner parts 41which eliminate the need for screw fixings. One pair of opposingvertical faces are panelled using a standard panel 42 of universal size.One of the second pair of opposing vertical faces is provided with astandard pressed or vacuum formed filter retainer panel 43 capable ofretaining a pre-filter (not shown). Each strut is provided with astandard hole pitch 44 in an internal flange 45.

[0050] The fully assembled frame construction with struts and cornerpieces is shown unpanelled in FIG. 5a and panelled in FIG. 5b. In orderto fix a panel 42, the satin aluminium finish of the struts 40 may beprimed and an acrylic adhesive tape and a compatible adhesive sealapplied. Panels 42 may be bonded into place whilst the seal is wetleaving no small internal gaps. The adhesive tape provides an instantbond while the liquid seal sets. This method of construction is quick,simple and lowers the skill level required for manufacture.

[0051]FIG. 6 illustrates a disassembled view of a plenum chamber. Asteel frame base 62 has a ladder like configuration coated on two sideswith a material of a preset tension which provides a specific pressuredrop contributing to perfect laminar flow (PLF). The base framecomprises two elongate side members 67 joined in parallel spaced apartrelationship by a plurality of transverse members 68. Each side member67 is adapted to fasten a light fitting at the position 65.

[0052] A profiled canopy 63 is bonded using a silicone bead seal to theupper face of the base frame to provide a smooth and interrupted airflowfrom the modular structure into a PLF material 64 mounted on the lowerface of the base frame. The profiled canopy has a substantially verticalend 69 defined by two side walls 70 joined in substantially parallelspaced apart relationship by an integral rear wall 71 which curvesinwardly away from the open end. Compressible foam seal 61 fits over a25 mm securing spigot 66 at the ends of the side walls and rear wall andpushes against a flat bulk head. The compression seal 61 represents theonly external seal of the plenum chamber and is fitted with a PLF panel80 to ensure even distribution of air across the width and down thelength of the plenum chamber. The plenum chamber is a clean, sealed unitensuring that air which has been filtered to 99.999995% isuncontaminated upon transmission to the operator booth.

[0053]FIG. 7 illustrates a unitary framework 102 of an embodiment of theinvention which is an alternative to that illustrated in FIGS. 4 and 5b.In this case, the unitary framework 102 comprises a plurality of unfirmsteel struts arranged vertically and horizontally (for example 103 and104) to form a regular box-like framework. Bonded to three faces of theunitary framework are steel panels 105 a, 105 b and 105 c. Theunpanelled front face 105 d is capable of retaining a pre-filter (notshown). This unitary framework 102 advantageously has no gaps.

What is claimed is:
 1. A modular containment assembly comprisingcomponents between which in use is induced an airflow, said componentsbeing: a modular structure comprising a plurality of unitary frameworksstacked to form a network of discrete housings; an operator booth ofbox-like configuration having a rear wall positioned adjacent to themodular structure, wherein the modular structure is adapted at or nearto its lower end to receive the airflow from the operator booth and ator near to its upper end to transmit the airflow to the operator booth,and the rear wall of the operator booth is adapted at or near to itslower end to transmit the airflow to the modular structure; and meansfor inducing the airflow downwardly in the operator booth.
 2. A modularcontainment assembly as claimed in claim 1 further comprising: a plenumarrangement adjacent to an open ceiling of the operator booth, whereinthe plenum arrangement is capable of transmitting the airflow from at ornear to the upper end of the modular structure downwardly into theoperator booth.
 3. A modular containment assembly as claimed in claim 2wherein the plenum arrangement comprises one or more plenum chambers. 4.A modular containment assembly as claimed in claim 3 wherein the or eachplenum chamber is adapted to contribute to perfect laminar flow (PLF).5. A modular containment assembly as claimed in claim 3 wherein the oreach plenum chamber comprises a base frame having a ladder-likeconfiguration.
 6. A modular containment assembly as claimed in claim 5wherein the base frame comprises two elongate side members joined inparallel spaced apart relationship by a plurality of transverse members.7. A modular containment assembly as claimed in claim 5 wherein on thelower face of the base frame is mounted PLF material.
 8. A modularcontainment assembly as claimed in claim 5 wherein a profiled canopy issecured to the upper face of the base frame.
 9. A modular containmentassembly as claimed in claim 8 wherein the profiled canopy has asubstantially vertical open end through which may be transmitted airflowfrom the modular structure.
 10. A modular containment assembly asclaimed in claim 9 wherein the substantially vertical open end isdefined by two side walls joined in substantially parallel spaced apartrelationship by an integral rear wall which curves inwardly away fromthe open end.
 11. A modular containment assembly as claimed in claim 10wherein the substantially vertical open end is fitted with a panel ofPLF material.
 12. A modular containment assembly as claimed in claim 1wherein the modular structure comprises: an at least partially openfront face at or near to its lower end and adjacent to the rear wall ofthe operator booth, wherein the rear wall of the operator booth at ornear to its lower end comprises an elongate gap capable of transmittingairflow from the operator booth to and through the at least partiallyopen front face of the modular structure.
 13. A modular containmentassembly as claimed in claim 12 wherein the at least partially openfront face is adapted to mount a pre-filter.
 14. A modular containmentassembly as claimed in claim 1 wherein each unitary framework is a metalframe construction.
 15. A modular containment assembly as claimed inclaim 14 wherein the metal is steel.
 16. A modular containment assemblyas claimed in claim 1 wherein one or more of the unitary frameworks ispanelled.
 17. A modular containment assembly as claimed in claim 16wherein the panels are steel panels.
 18. A modular containment assemblyas claimed in claim 1 wherein each unitary framework comprises aplurality of struts.
 19. A modular containment assembly as claimed inclaim 18 wherein the struts are uniform.
 20. A modular containmentassembly as claimed in claim 18 wherein each strut of the unitaryframework has a uniform drill pattern.
 21. A modular containmentassembly as claimed in claim 1 wherein one or more of the unitaryframeworks is box-like.
 22. A modular containment assembly as claimed inclaim 1 wherein at least one unitary framework is adapted to verticallymount a filter.
 23. A modular containment assembly as claimed in claim22 wherein the at least one unitary framework is positioned at or nearto the lower end of the modular structure.
 24. A modular containmentassembly as claimed in claim 1 wherein at least one unitary framework isadapted to horizontally mount a filter.
 25. A modular containmentassembly as claimed in claim 24 wherein the at least one unitaryframework is positioned above the lowermost unitary framework of themodular structure.
 25. A modular containment assembly as claimed inclaim 1 wherein at least one unitary framework is adapted to mount a fanunit.
 26. A modular containment assembly as claimed in claim 25 whereinthe at least one unitary framework is positioned at or near to the upperend of the modular structure.
 27. A modular containment assembly asclaimed in claim 1 wherein the means for inducing the airflow comprisesa fan unit driven by a flange mounted inverter controlled motor.
 28. Amodular containment assembly as claimed in claim 1 wherein the operatorbooth comprises individual panels capable of being locked together.